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Research Article
Effect of the Die Temperature and Blank Thickness on the
Formability of a Laser-Welded Blank of a Boron Steel Sheet with
Removing Al-Si Coating Layer
Copyright © 2014 M. S. Lee et al. This is an open access article distributed under the Creative Commons Attribution License, which
permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited.
Reducing carbon emissions has been a major focus in the automobile industry to address various environmental issues. In particular,
studies on parts comprised of high strength sheets and light car bodies are ongoing. Accordingly, this study examined the use of
boron steel, which is commonly used in high strength sheets. Boron steel is a type of sheet used for hot stamping parts. Although it
has high strength, the elongation is inferior, which reduces its crash energy absorption capacity. To solve this problem, two sheets
of different thickness were welded so the thin sheet would absorb crash energy and the thick sheet would work as a support. Boron
steel, however, may show weakening at the welding spot due to the Al-Si coating layer used to prevent oxidation from occurring
during the welding process. Therefore, a certain part of the coating layer of a double-thickness boron steel sheet that is welded in
the hot stamping process is removed through laser ablation, and the formability of the hot-work was examined.
C Mn Si P S Al Cr B
0.22 1.20 0.20 0.02 0.005 0.02 0.10 0.002
as FeAl3 or Fe2Al5 , form due to the effect of the coating Table 2: Ablation condition.
layer. FeAl3 or Fe2Al5 decreases the ductility of the material, Power (w) Speed (mm/sec) Count Frequency
making it brittle. Ehling et al. [17] found that hardness of
20 300 1 60
coated boron steel decreased to 300∼320 Hv and Moon et al.
[18] reported that tensile strength and elongation decreased
after laser welding because of the effect of the coating Table 3: Specimen with and without Al-Si coating layer.
layer. Therefore, the welding of boron steel would involve
the removal of a certain portion of the coating layer. This Experiment number Method of ablation Side of ablation
study examined the mechanical characteristics of boron steel Experiment number 1 Sandpaper Double side
welded after removing the Al-Si coating layer. In addition, the Experiment number 2 Laser Double side
die temperature and dome height for the ideal mechanical Experiment number 3 Laser Upper side
strength were evaluated based on the hot Erichsen test, which Experiment number 4 Laser Under side
simulates the hot stamping process under ideal conditions, as Experiment number 5 Without ablation —
shown in Figure 1.
Spot size
diameter
Laser beam
g
ldin n Tensile test and hardness test
Weirectio
d Process speed
Apply optimal
ablation condition
Upper view Side view
Specimen after Erichsen test
Formability was evaluated according to
die temperature and blank thickness
(a) (b)
Figure 1: Schematic diagram for laser welding and Erichsen experiment. (a) Laser ablation and laser welding, (b) Erichsen test with optimal
ablation.
Steel
50 𝜇m
(a) Boron steel sheet (b) Quenching after 950∘ C heating state about 5 minutes
Figure 2: Microstructure in cross section before and after quenching of boron steel.
(a) Before laser ablation of boron steel sheet surface (b) After laser ablation of Al-Si coating layer
Figure 3: Laser ablation of Al-Si coating layer of boron steel sheet surface before welding.
4 Advances in Mechanical Engineering
50 𝜇m
(a) Before laser ablation (b) After laser ablation of Al-Si coating layer
Figure 4: Microstructure in cross section before and after laser ablation of boron steel.
Fiber
Camera
Camera
monitor
Welding
head
N2 shield
gas
Welding
jig
(c) Specimen before die quenching (d) Specimen after die quenching
Figure 5: Laser welding equipment and specimen before and after die quenching.
A bonded part, whose mechanical characteristics become the steel sheet after welding, the burr after shearing was
inferior after welding, was formed at the HAZ (heat affected removed, fixed on the tool, and laser-welded.
zone) between the base material and welding part, which
is the cause of embrittlement. The HAZ reduces because it
is close to the ideal welding condition. Equation (1) is the 3. Evaluation on the Mechanical
expression of the welding heat input: Characteristics
3.1. Tensile Test. For boron steel welded after laser abla-
𝑃𝑙
𝑄 = 𝜂𝑙 , (1) tion under each condition, 6 specimens were machined
𝜋ℎ𝑟2 according to ASTM E 8M (totally 30 specimens). Three
tensile tests were performed on each sample before and after
𝜂𝑙 : laser coefficient, 𝑃𝑙 : laser power, 𝑟2 : laser beam size, and ℎ: die quenching. The values except the highest and lowest
steel sheet thickness. were used for further analysis. Figures 6(a) and 6(b) show
Figure 5 shows laser equipment and specimen before and the tensile strength before quenching and after quenching,
after die quenching. To reduce the two misalignments of respectively. Experiment number 6 was added to compare the
Advances in Mechanical Engineering 5
800 1600
2
600 1200 1
Engineering stress (MPa)
200 400
0 0
0.00 0.05 0.10 0.15 0.20 0.25 0.30 0.00 0.01 0.02 0.03 0.04 0.05 0.06 0.07 0.08 0.09 0.10
Engineering strain (mm/mm) Engineering strain (mm/mm)
(1) Experiment number 1 (4) Experiment number 4 (1) Experiment number 1 (4) Experiment number 4
(2) Experiment number 2 (5) Experiment number 5 (2) Experiment number 2 (5) Experiment number 5
(3) Experiment number 3 (6) Base metal (22MnB5) (3) Experiment number 3 (6) Base metal (22MnB5)
(a) Tensile strength of specimen before die quenching (b) Tensile strength of specimen after die quenching
B Spectrum 12
Fe
Cr Fe
P
Mn Mo Mn
C Si
Ti S
Al Fe
Ti Cr
1 mm Electron image 1 0 2 4 10 6 8 12 14 16 18 20
(keV)
Full scale 1338 cts cursor: 0.000
Element B C Al Si P Cr Mn Fe Ni
Weight (%) 0.41 2.2 1.89 2.06 −6.56 0.58 4.59 85.2 3.07
five laser ablation variables with the base metal of boron steel and 3%, respectively. During welding, chemical compounds,
(22MnB5). such as FeAl3 or Fe2 Al5 , form due to the effect of the coating
Among the specimens to which the laser ablation had layer. FeAl3 or Fe2 Al5 decreases the ductility of the material,
been applied, the experiment number 2 specimen with laser making it brittle. Figure 7 shows the EDS (energy disper-
ablation on both sides showed the highest percentage elon- sive spectroscopy) data of the welding zone of experiment
gation, whose tensile strength and elongation were 585 MPa number 1. In experiment number 1, the coating layer was
and 20%, respectively. For experiment number 3 with the removed by sandpaper. In this case, because Al-Si was not
laser ablation only on the upper side of the specimen, the deleted completely, Al and Si were melted and compounds,
values were 603 MPa and 18%. For the experiment number such as FeAl3 or Fe2 Al5 , formed in the welding metal zone
1 specimens, whose coating layer had been removed using during welding. Table 5 lists the EDS analysis of the welding
sandpaper, the tensile strength and elongation were 604 MPa zone according to the ablation method (the negative value
and 16%, respectively. For the experiment numbers 4 and 5 means that Al and Si could not be found). This can explain
specimens, whose lower part only underwent laser ablation why the coating layer affected the tensile stress and elongation
and did not undergo laser ablation, respectively, the values in the tension test. Although the elongation value was lower
were 603 MPa and 599 MPa and 14% and 16%, respectively. than that of the base metal, the tensile strength meets the
Regarding the condition after quenching, experiment minimum requirements for the hot stamping parts in the
number 2 with ablation on both sides had values of 1451 MPa automobile industry (1450 MPa). The remaining specimens
6 Advances in Mechanical Engineering
T (top)
HAZ
HAZ
Base metal Base metal
M (middle)
B (bottom)
Experiment number 1 Experiment number 2 Experiment number 3 Experiment number 4 Experiment number 5
T (top)
Al 1.89 −0.94 3.25 5.97 1.83
Si 2.06 −2.40 1.52 6.86 2.15
M (middle)
Al 0.52 −0.83 −0.40 −0.48 2.46
Si 0.86 −2.12 −0.51 −0.40 3.23
B (bottom)
Al 1.26 −0.76 2.64 −0.35 6.63
Si 1.63 −2.89 3.36 −0.66 7.33
HAZ
500
1
mounted using a poly coat and hardener. The surface was
300 then smoothed by polishing, and the hardness was measured
using a Vickers hardness test. The load was set to 1000 g,
200 and the hardness was measured at every 0.25 mm (250 𝜇m).
The hardness of the experiment number 2 and experiment
100 number 5 samples before and after quenching was compared.
2 As shown in Figure 8, the specimens before quenching
0 showed similar results. Regarding the weld zone, the Vickers
−30 −20 −10 0 10 20 30 hardness of the martensite structure and base metal was
Distance from weld line, x (mm) 450–550 Hv and 180–200 Hv, respectively. In contrast, the
1 Top specimens after quenching showed a different distribution
2 Middle over the weld zone, as shown in Figure 9. Although the
3 Bottom experiment number 2 specimen, with laser ablation on both
sides, showed an even distribution, the weld zone exhibited
Figure 8: Distribution of Vickers hardness in the specimens before a slightly higher hardness than that of the base metal.
die quenching of experiment numbers 1∼5. For experiment number 5, the hardness of the weld zone
decreased to 250–300 Hv. Figure 10 shows SEM images of the
specimens. Figure 10(a) reveals a complete transformation to
exhibited inferior tensile strength and elongation. Regarding martensite, whereas (b) indicated the presence of both ferrite
the breaking location, cracks were observed at the HAZ (heat and martensite. A comparison of the SEM images in Figure 10
affected zone). Although the WZ (weld zone) and base metal with the tensile strength showed that the boron steel needs to
all transformed to a martensitic structure, the hardness and undergo laser ablation on both sides before welding.
strength in the HAZ at the area between the base metal and
fusion zone upon welding were inferior. Experiment number 4. Erichsen Test
2 showed the best tensile strength before and after quenching
due to the removal of the coating layers at both sides. 4.1. Test Tools and Methods. The Erichsen test is a stan-
In contrast, the mechanical properties of the experiment dardized test of the material forming characteristics. A steel
Advances in Mechanical Engineering 7
600 600
500 500
400 400
Hardness (Hv)
Hardness (Hv)
300 300
200 200
HAZ
HAZ
HAZ
HAZ
100 Laser ablation specimen 100
Specimen without ablation
with double side x
x
0 0
−30 −20 −10 0 10 20 30 −30 −20 −10 0 10 20 30
Distance from weld line, x (mm) Distance from weld line, x (mm)
1 Top 1 Top
2 Middle 2 Middle
3 Bottom 3 Bottom
(a) Experiment number 2 (b) Experiment number 5
Figure 10: Microstructure of weld zone after die quenching of experiment numbers 2, 5.
sheet was pressurized with a die holder and the height was The base metals were 1.2𝑡 and 1.6𝑡 and both sides of the
measured using a punch to test the difference in hardness. specimen of the LWB (laser welded blank) (1.2𝑡 + 1.6𝑡) under-
Equation (2) shows the Erichsen index (EI%) according to went laser ablation and welding. These samples underwent
whether the forming characteristics are satisfactory as the forming at normal temperatures and hot forming. The die
limit of the specimen welded reaches 70% of that of the base temperature in hot forming was divided into four groups
metal. Figure 11 presents a diagram of the Erichsen test mold because hot stamping involved forming and quenching on a
and die and includes photographs of the mold and devices steel sheet at 950∘ C simultaneously. A number of processes
used in the experiment: increased the temperature of the mold, which affected the
forming characteristics and mechanical strength of the prod-
uct as well as the flow of cooling water (energy). Therefore,
Laser welded blank in this experiment, the forming temperature was divided
Erichsen Index (%) = × 100. (2)
Base metal into four different conditions to comparatively evaluate the
mechanical characteristics based on the hardness of the
The experiment can be carried out at normal temperature specimens and forming characteristics.
and in hot forming. For hot forming, the heat cartridge was
installed for both the mold and punch, as shown in Figure 11. 4.2. Hot Forming. Figure 12 shows the result of the hot
Table 6 lists the experiment conditions. forming test according to the temperature variables of the
8 Advances in Mechanical Engineering
40
5
Upper die
30
(mm)
Punch
0.75
33
10 80 Lower die
10
10
6∘ 2
110
45
∅33 5 R10
Figure 11: Schematic and equipment of die and punch for Erichsen test.
22 12 22 12
20 20
18 10 18 10
16 16
Dome height (mm)
14 8 8
14
12 12
6 6
10 10
8 8
4 4
6 6
4 2 4 2
2 2
0 0 0 0
R.T 100 200 300 R.T 100 200 300
Temperature (∘ C) Temperature (∘ C)
16
14 8
12
6
10
8 4
6
4 2
2
0 0
R.T 100 200 300
Temperature (∘ C)
Figure 12: Punch load and dome height of hot Erichsen test according to sheet thickness and die temperature.
Advances in Mechanical Engineering 9
Hardness (Hv)
Base Metal 1.2 12 100
Base Metal 1.2 12 200 400
Base Metal 1.2 12 300
1.2t + 1.6t
Base Metal 1.6 12 R.T (25∘ C) Laser welded blank
Base Metal 1.6 12 100 300 A B CD E
(3) The Erichsen index (EI%) of the LWB specimen [8] Y. S. Suh, M. W. Ji, K. H. Lee, and Y. S. Kim, “Application
increased at temperatures higher than 200∘ C and and verification of virtual manufacturing to hot press forming
the dome height in hot forming was in the order of process with boron steel,” Transactions of the Korean Society of
1.6𝑡, LWB, and 1.2𝑡. For EI (%), the value of the LWB Mechanical Engineers, vol. 18, no. 2, pp. 61–66, 2010.
was 90% that of 1.6𝑡 and 105–110% of 1.2𝑡, indicating [9] D. Anand, D. L. Chen, S. D. Bhole, P. Andreychuk, and G.
satisfactory forming characteristics. Boudreau, “Fatigue behavior of tailor (laser)-welded blanks for
automotive applications,” Materials Science and Engineering A,
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was conducted under 200∘ C. Based on the hot form- [10] R. Padmanabhan, A. J. Baptista, M. C. Oliveira, and L. F.
ing test, according to the die temperature, to maintain Menezes, “Effect of anisotropy on the deep-drawing of mild
the mechanical characteristics for hot stamping parts, steel and dual-phase steel tailor-welded blanks,” Journal of
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Conflict of Interests
[12] R. Sharma, P. Molian, and F. Peters, “Geometric variability and
The authors declare that there is no conflict of interests surface finish of weld zones in Yb:YAG laser welded advanced
regarding the publication of this paper. high strength steels,” Journal of Manufacturing Processes, vol. 12,
no. 2, pp. 73–84, 2010.
[13] H. S. Choi, B. M. Kim, G. H. Park, and W. S. Lim, “Optimization
Acknowledgments of resistance spot weld condition for single lap joint of hot
stamped 22MnB5 by taking heating temperature and heating
This study was supported by the Human Resources Devel- time into consideration,” Transactions of the Korean Society of
opment of the Korea Institute of Energy Technology Mechanical Engineers A, vol. 34, no. 10, pp. 1367–1375, 2010.
Evaluation and Planning (KETEP) Grant funded by the [14] J. K. Choi, J. G. Kim, S. M. Shin, C. H. Kim, and S. H. Rhee,
Korean Government, Ministry of Knowledge Economy (no. “A study on laser welding caracteristics of 1500MPa grade ultra
20104010100540), and National Research Foundation of high strength steel for automotive application,” Journal of the
Korea (NRF) grant funded by the Korean Government Korean Society of Logopedics and Phoniatrics, vol. 13, no. 3, pp.
(MEST) (Grant no. 2012-0001204). 19–26, 2010.
[15] Y. G. An, C. Y. Kang, Y. S. Kim, C. H. Kim, and T. K. Han,
“Microstructure and hardness of DISK laser welded in Al-Si
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